FE-Simulation Based Design of Wear-Optimized Cutting Edge Roundings

Bergmann, Benjamin; Denkena, Berend; Beblein, Sascha; Picker, Tobias

doi:10.3390/jmmp5040126

Cited by 6 publications

(3 citation statements)

References 24 publications

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“…The planing test rig is used to measure the process force and to calculate the local normal stress σ and tangential stress τ at the cutting edge according to the method of Bergmann [29]. This method was used in [54] to determine the internal stresses of the cutting wedge during planing, as well in order to determine the mechanical load in wet metal cutting [55] and in combination with FE-based simulations to determine wearoptimised cutting edge microgeometries [56]. In the experiments, the cutting speed (V c ) is varied in three steps.…”

Section: Comparison With In Situ Measured Coefficient Of Friction Dur...mentioning

confidence: 99%

Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester

Nassef,

Pape,

Poll

et al. 2024

Lubricants

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Predicting the tribological behaviour in the secondary shear zone in the metal-cutting processes is considered a significant challenge in contemporary research. This work investigated the frictional performance in the secondary shear zone of a planing process using a modified ball-on-disc open tribometer. The values of the coefficient of friction (COF) were tracked between an AISI4140 + QT disc (chip) and a cemented carbide ball (cutting tool) coated with TiAlN under three contact pressures of 0.5, 1, and 2 GPa at a range of sliding speeds starting from 0.2 m/s to 1.6 m/s. The tests were conducted under both dry and lubricated conditions using three commercial cutting fluids of CSF 35 straight oil, Vasco 6000, and Zubora 67H emulsions. Also, the MWFs were tested for their rheological properties and wettability. The tribometer results validated the same COF trend as that in the actual metal-cutting experiments, particularly at 0.5 and 1 GPa in dry conditions. Moreover, Zubora 67H emulsion is proven to be the optimal choice due to it reducing the COF between the rubbing contacts by up to 78%. Furthermore, it showed the lowest contact angle and viscosity index, revealing its ability to easily penetrate, especially at higher temperatures, within the secondary cutting zone.

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Section: Comparison With In Situ Measured Coefficient Of Friction Dur...mentioning

confidence: 99%

Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester

Nassef,

Pape,

Poll

et al. 2024

Lubricants

Self Cite

View full text Add to dashboard Cite

show abstract

“…Zhao et al [18] established a simulation model of tool milling steel to optimize the tool edge parameters and conducted orthogonal tests, which showed that the depth of wear of the milling cutter decreases and then increases with the increase of the shape factor, which is consistent with the simulation results. Bergmann et al [19] proposed a new method for the design of the cutting-edge rounding angle based on the finite element simulation model and test, and the optimal value of the cutting-edge rounding angle was obtained by combining it with the wear model. Fang et al [20] investigated the effect of tool wear on cutting force and vibration in Inconel 718 turning and found that tool edge wear increases with increasing edge radius.…”

Section: Introductionmentioning

confidence: 99%

A synchronous wear design for inner and outer inserts of indexable drill based on numerical simulation

Li,

Jiang,

Wang

et al. 2024

Preprint

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The synchronous wear of the inner and outer inserts is vital for the indexable drill with stable high-performance stability throughout life. In this study, the finite element simulation model for the indexable drill is developed, in which the accurate material constitutive model considering the strain rate and thermal softening is established experimentally. The synchronous wear design of the inner and outer inserts is implemented based on finite element simulation. The initial radial force is optimized before the synchronous wear design. Then, the wear rates of inner and outer inserts are predicted based on the temperature and stress of tools extracted from the simulations and the classical wear model, which is used for the synchronous wear design. The results show that the calculated tool wear rates for inner and outer inserts are close to each other when the tool edge radius, rake angle and relief angle are 20 µm, 8° and 4°, respectively. The synchronous wear could also be achieved for different process parameters based on the optimized parameters of the insert.

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“…In the presented analysis in manufacturing companies, we came across this phenomenon, i.e., a lack of funds. This presented solution would certainly not burden the companies’ budget considerably, as it would practically only replace the active parts of the forming equipment, which would speed up this work, make it more attractive, and would make it relatively easy for any just-trained worker and increase safety at work [ 17 , 18 , 19 , 20 , 21 , 22 , 23 ].…”

Section: Introductionmentioning

confidence: 99%

An Application of a Magnetic Impulse for the Bending of Metal Sheet Specimens

2022

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Currently, classical methods for the creation of various shapes and bending angles of metal sheet parts are applied. They are represented by the so-called all-metal forming tools. Non-standard methods, which in some cases exceed conventional technical solutions, are used in the practice to a minor extent. This is an area of interest from the point of view of ecology, because the shaping process performed in this way does not burden the environment in any considerable way. The knowledge presented in this work is obtained based on experiments in laboratory conditions. The list of literature contains mainly works from the recent period. The research represents a contribution to the great mosaic of magnetism. The aim of the current paper is to also verify the possibilities of the suitability of a special tool in the formation of metal sheet specimens using the application of the so-called forming with a free core. Additional benefits of the experimental work and their results are anticipated. The contribution is complemented by detailed calculations and diagrams. The practical contribution and research is that the device used for forming has been successfully tested. It turns out that the presented method is suitable for further development. The method has proven that is it suitable for industrial applications where simple shapes are produced.

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FE-Simulation Based Design of Wear-Optimized Cutting Edge Roundings

Cited by 6 publications

References 24 publications

Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester

Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester

A synchronous wear design for inner and outer inserts of indexable drill based on numerical simulation

An Application of a Magnetic Impulse for the Bending of Metal Sheet Specimens

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